Electrical cable connector means and method of terminating such cable



Sept. 8, 1964 R. 'R. BROWN 3,148,011 ELECTRICAL CABLE CONNECTOR MEANSAND METHOD OF TERMINATING SUCH CABLE Ongmal Flled Nov. 17, 1958 2Sheets-Sheet l FIG.I

' as 94 96 80 a2 INVENTOR ROBERT R. BROWN ATTORNEY pt. 8, 1964 R. R.BROWN 3,148,011

, ELECTRICAL CABLE CONNECTOR MEANS AND METHOD CABLE 0F TERMINATING, SUCH958 2 Sheets-Sheet 2 Original Filed Nov. 17-, 1

21 v2 02 N9 on mm mm mm 8. mm

United States Patent LECTRICAL CABLE CONNECTOR MEANS AND E METHUD 0FTERMINATING SUCH CABLE Robert R. Brown, Bernardsville, N.J., assignor toElastic Stop Nut Corporation of America, Union, N.J., a cororation ofNew Jersey Co irtinuation of application Ser. No. 774,456, Nov. 17,

1958. This application Aug. 2, 1962, Ser. No. 215,483

7 Claims. (Cl. 339-218) This is a continuation of copending applicationSerial No. 774,456, filed November 17, 1958, now abandoned.

This invention relates to electrical cable connector means and to amethod of terminating such cable.

It is desirable in the use of electrical cables and part1cularly in theinstallation of a system in which the cables and other components (suchas transformers, reactors, motors, potheads, etc.) are directly buriedin the ground, placed on or above the ground and hence exposed tosunlight, or immersed in fresh or even salt water, to be able releasablyto join, electrically and mechanically, cable ends to each other as wellas to other components at locations determined primarily by conditionsencountered in the field during installation and which are more or lessunpredictable in advance of actual installation.

It is known to provide the ends of predetermined cable lengths, andother components at the factory with integral connectors which canreadily be plugged together by hand in the field to provide a releasablewaterproof connection between two such cable lengths or between one suchcable length and another component. Such connectors, as applied to cablelengths, are, however, sub ect to the dis advantage that the cablelengths are predetermined thus entailing a handicap in the field. Also,where such connectors are used the cable must be handled twice,resulting in added expense.

Various proposals have been made for overcoming the above problem, butmost have been subject to serious disadvantages, either as to originalcost, complexity of use and/ or unsatisfactory performance. One involvesthe use of molding equipment in the field and another produces aconnection which is not releasable.

This invention provides a releasable waterproof and gasproof electricalconnection and means for making such a connection in a way whichcompletely solves the above problem.

Accordingly important objects of the invention are to provide areleasable waterproof electrical connection which can readily be made atany desired location during installation of a system of the typereferred to.

In one aspect the invention contemplates an electrical fitting in theform of a socket member, an electrical fitting in the form of a plugmember and a housing for each fitting. In use the ends of two cablelengths to be joined are skived to expose the conducting means thereof,the fit tings are afiixed to the conducting means and are then insertedinto the respective housings. The connection is completed by thereuponsliding the plug member into frictional engagement with the socketmember; simultaneously the housings frictionally engage each other toprovide a waterseal.

A predetermined amount of insulating mastic material is preferablypreinserted into each housing to fill voids, retard corona, excludemoisture and gases and ease assembly.

Therefore additional important objects of the invention are to providean electrical connection and means for making such connection in whichinternal voids are filled with insulating material, corona resistance isexceptional, resistance to the entry of moisture and gases isexceptional and assembly is readily accomplished.

The above and further objects and advantages will appear from thefollowing description of a preferred example of the invention and theaccompanying drawings thereof wherein:

FIG. 1 is a longitudinal elevation of one of the fittings affixed to theconducting means of a cable;

FIG. 2 is an axial sectional view of the housing for the fitting of FIG.1;

FIG. 3 is a view similar to FIG. 2 but showing mastic material in thehousing;

FIG. 4 is a view showing the fitting of FIG. 1 in longitudinal elevationand the housing of FIG, 3 after the former has been fully inserted intothe latter;

FIG. 5 is a view on line 55 of FIG. 2;

FIG. 6 is a view on line 6-6 of FIG. 4;

FIG. 7 is a longitudinal elevation of the other fitting afiixed to theconducting means of another cable;

FIG. 8 is an axial sectional view of the fitting of FIG. 7;

FIG. 9 is a View on line 99 of FIG. 8;

FIG. 10 is an axial sectional view of the housing for the fitting ofFIG. 7;

FIG. 11 is a view similar to FIG. 12 but showing mastic material in thehousing;

FIG. 12 is a view on line 12-12 of FIG. 10; and

FIG. 13 is a view showing the fittings in longitudinal elevation and thehousings in axial section, with the fittings engaging each other and thehousings engaging each other, completing an electrical connectionbetween the two cables.

The drawings show means for releasably making a waterproof electricalconnection between conducting means 14 (FIG. 4) of a first cable 16(FIGS. 1, 4 and 13) having an outer jacket 18 and inner insulation 19and conducting means 20 (FIG. 7) of a second cable 22 (FIGS. 7 and 13)having an outer jacket 24 and inner insulation 25. Conducting means 14and 20 are as shown wires.

The means for making the connection include an electrical fitting in theform of an elongate metallic plug member 26 (FIGS. 1, 4 and 13) definingan axis, an electrical fitting in the form of an elongate metallicreceptacle or socket member 28 (FIGC. 7, 8 and 13) defining an axis, atubular housing 30 (FIGS. 2 through 6 and 13) defining an axis and ofresilient insulating material for plug member 26 and a tubular housing32 (FIGS. 10 through 13) defining an axis and of resilient insulatingmaterial for socket member 28.

Plug member 26 has at one end a socket portion 34 adapted for permanentattachment to wires 14 of cable 16. Socket portion 34 has a malleabletubular wall into which the bared ends of wires 14 of cable 16 areinserted after which the tubular wall may be crimped in known manner toeffect a permanent mechanical and electrical connection between plugmember 26 and wires 14. A crimped area is shown at 36.

Likewise, socket member 28 has at one end a socket portion 38 adaptedfor permanent attachment to wires 20 of cable 22. Socket portion 33 hasa malleable tubular wall into which the bared end of wires 20 areinserted after which the tubular wall may be crimped in known manner toeffect a permanent mechanical and electrical connection between socketmember 28 and wires 20. A crimped area is shown at 40.

Following the attachment of plug member 26 to cable 16 and of socketmember 28 to cable 22 as aforesaid, the insulation and jackets of cables16 and 22 are preferably beveled adjacent members 26 and 28 as shown at37 and 39, respectively.

The end of plug member 26 remote from socket portion 34 has a solid plugportion 42 including a first cylindrical part 41 remote from socketportion 34 and a coaxial second cylindrical part 43 between part 41 andsocket portion 34 and of greater diameter than part 41. Parts 41 and 43are joined by a frusto-conical surface 45.

The end of socket member 28 remote from socket portion 38 has acylindrical socket or receptacle portion 44 which, by virtue of a pairof diametrically opposite longitudinal slits 46 (FIG. 9), is somewhatresilient radially. To control the resiliency just referred to it may bedesirable to provide socket member 28 with a longitudinally split sleeve48 (which may be deemed a part of member 28) of resilient material suchas beryllium copper embracing and frictionally engaging socket portion44. Preferably sleeve 48 is oriented so that slits 46 are completelycovered. One end of sleeve 48 coincides substantially I V with the openend of socket portion 44. For a reason which will be brought out it isdesirable to provide means for maintaining sleeve 48 in the describedand illustrated position with respect to socket member 28. Accordingly'socket member 28 is provided with an annular external stop 50 extendingtherearound between socket portions '38 and 44. Stop 58 can convenientlybe formed by rolling an external shoulder around socket member 28. Asshown the other end of sleeve 48 engages stop 58. The

normal inside diameter of socket portion 44, with sleeve 48 installedthereon, is slightly less than the diameter of plug part 41, so thatsocket portion 44 is adapted to receive plug part 41 in snug engagementtherewith, electrically to connect wires 14 and 28.

Part 41 of plug member 26 is insertable into and removable from socketportion 44 by hand. This insertion is facilitated by an internal bevel52 at the open end of socket portion 44 and is accompanied by an elasticradial expansion of socket portion 44 and sleeve 48.

Between socket portion 34 and plug portion 42 plug member 26 has a pairof longitudinally spaced confronting shoulders 54 extending around plugmember 26. Shoulders 54 are frusto-conical so as to be furthest fromeach other at the radially outer parts thereof. Shoulders 54 are ineffect mirror images of each other.

Between socket portion 38 and stop 58 socket member 28 has a pair oflongitudinally spaced confronting shoulders 56 extending around socketmember 28. Shoulders 56 are frusto-conical so as to be furthest fromeach other at the radially outer parts thereof. Shoulders 56 are ineffect mirror images of each other.

Between that shoulder 54 remote from socket portion 34 and plug part 43of plug member 26 there is a frustoconical surface 58 which tapers fromplug part 43 to the outer diameter of shoulder 54. That shoulder 54referred to in this paragraph and frusto-conical surface 58 are joinedby a cylindrical surface 68 of somewhat greater diameter than plug part43.

Shoulders 54 are joined by a cylindrical surface 62 which as shown is ofthe same diameter as plug part 43.

Joining that shoulder 54 adjacent socket portion 34 is a cylindricalsurface 64 of the same diameter as and coaxial with surface 60 andextending toward socket portion 34 from that shoulder 54. Joiningsurface 64 and the exterior of socket portion 34, the diameter of whichis intermediate the diameters of surfaces 62 and 64, is a plane annularsurface 66 perpendicular to the axis of plug member 26.

The normal outside diameter of socket portion 44 may be approximatelythe same as the diameter of surface 68, and shoulders 56 are joined by acylindrical surface 68 of the same diameter and axial length as surface'62.

Joining that shoulder 56 adjacent socket portion 38 is a cylindricalsurface 70 of the same diameter as and a coaxial with the outer surfaceof socket portion 44 and of surfaces 68 and 78, is a plane annularsurface 72 perpendicular to the axis of socket member 28.

The purpose of shoulders 54 and 56 and surfaces 62 and 68 and relatedparts of plug and socket members 26 and 28 will appear. Sufiice it tosay for the present that plug member 26 thus has an intermediate portionhaving circumferential flanges and a circumferential groovetherebetween, provided by shoulders 54 and surface 62, and socket member28 has an intermediate portion having circumferential flanges and acircumferential groove therebetween, provided by shoulders 54 andsurface 62, and socket member 28 has an intermediate portion havingcircumferential flanges and a circumferential groove therebetween,provided by shoulders 56 and surface 68.

Housing 38 has plane ends 74 and 76 and an opening 78 therethrough fromend 74 to end 76. Plug member 26 is adapted to be inserted by hand, plugportion 42 first, into opening 78 from end 74, as will appear in moredetail.

Opening 78 has a portion indicated generally at 88 between ends 74 and76 and adapted for interengagement with the intermediate portion of plugmember 26 to limit the aforesaid insertion thereof into and to hold plugmember 26 in predetermined position with respect to housing 38. Morespecifically, as shown, housing 38 has at portion 88 a pair of axiallyspaced frusto-conical shoulders 82, which in effect are mirror images ofeach other, and which are joined at the radially inner peripheriesthereof by a cylindrical surface 84. The normal axial length of surface84 is slightly less than the axial length of surface 62 of plug member26 and the normal diameter of surface 84 is slightly greater than thediameter of surface 62. The diameter of plug part 43 is preferablysubstantially equal to the normal diameter of surface 84. Shoulders 54and 82 are inclined with respect to the axes thereof at the same angle,which in the illustrated example is about 75 degrees.

Opening 78 also has a generally cylindrical portion indicated generallyat 86 between portion 88 and end 74 and in open communication with thelatter and adapted to receive therein socket portion 34 of plug member26 and to receive therein and snugly engage a portion of jacket 18 ofcable 16. The end of portion 86 at end 74 is chamfered as indicated at87.

Opening 78 further has a cylindrical portion indicated generally at 88between portion 88 and end 76 and in open communication with the latterand adapted to receive and snugly engage plug part 43 of plug member 26.

Between portions 88 and 86 and joining that shoulder 82 adjacent portion86 is a cylindrical surface 98 of the same diameter as but slightlylarger in axial length than surface 64. Joining the axial end of surface98 adjacent portion 86 and portion 86 is a frusto-conical surface 92.

Between portions 88 and 88 and joining that shoulder 82 adjacent portion88 is a cylindrical surface 94 of the same diameter as but slightlylarger in axial length than surface 68. Joining the axial end of surface94 adjacent portion 88 is a frusto-conical surface 96 which conforms inshape and size to surface 58 of plug member 26.

Extending from portion 86 through portion 88 and portion 88 to end 76 isa longitudinal keyway or vent passage 98 at one side of opening 78 andin open communication with portion 86 and end 76 and in effect forming apart of opening 78.

Housing 38 further has an external cylindrical surface 188 locatedsubstantially radially outwardly from portion 88 of opening 78. The endof surface 188 remote from end 76 is defined by a plane annular surface182 perpendicular to the axis of housing 38. As shown the plane ofsurface 182 intersects surface 86.

Joining the radially outer periphery of surface 182 and end 74 is acylindrical surface .184.

Joining the end of surface 188 remote from surface 182 and end 76 is afrusto-conical surface 186 which in the illustrated example makes anangle of about 45 .degrees with the axis of housing 38.

Housing 32 has plane ends 188 and 118 and an opening 112 therethroughfrom end 188 to end 118. Socket member 28, with sleeve 48 assembledtherewith as aforesaid, is adapted to be inserted by hand, socketportion 44 first, into opening 112 from end 188, as will appear in moredetail.

Opening 112 has a portion indicated generally at 114 between ends 188and 118 and adapted for interengagement with the intermediate portion ofsocket member 28 to limit the aforesaid insertion thereof into and tohold socket member 28 in predetermined position with respect to housing32. More specifically, as shown, housing 32 has at portion 114 a pair ofaxially spaced frustoconical shoulders 116, which in effect are mirrorimages of each other, and which are joined at the radially innerperipheries thereof by a cylindrical surface 118. The normal axiallength of surface 118 is slightly less than the axial length of surface68 of socket member 28 and the normal diameter of surface 118 isslightly greater than the diameter of surface 68. Shoulders 56 and 116are inclined with respect to the respective axes thereof at the sameangle, which in the illustrated example is about 75 degrees.

Opening 112 also has a generally cylindrical portion indicated generallyat 128 between portion 114 and end 108 and in open communication withthe latter and adapted to receive therein socket portion 38 of socketmember 28 and to receive therein and snugly engage a portion of jacket24 of cable 16. The end of portion 124) at end 188 is chamfered asindicated at 122.

Opening 112 further has a cylindrical portion indicated generally at 124between portion 114 and end 111) and in open communication with, butterminating short of end 118.

Between portions 114 and 128 and joining that shoulder 116 adjacentportion 128 is a cylindrical surface 126 of the same diameter as butslightly larger in axial extent than surface 78. Joining the axial endof surface 126 and portion 128 is a frusto-conical surface 128.

Portion 124 of opening 112 has a cylindrical surface 130 extending fromone end thereof to the other and joining that shoulder 116 adjacent end118 at the outer periphery thereof. The axial length of surface 130 isslightly greater than the axial length of socket member 28 from theouter periphery of that shoulder 56 adjacent socket portion 4-4 to theopen end of socket portion 44. Surface 138 is adapted to receive socketportion 44 and sleeve 48 and snugly engage the latter.

Opening 112 has a further portion indicated generally at 132 betweenportion 124 and end 118 and in open communication with the latter.Portion 132 includes a cylindrical surface 134 joining end 118 andextending therefrom toward portion 124 and normally of slightly lessdiameter than surface 188 and adapted to receive surface 188 therein ina snug fit to produce therewith a Waterseal between housings 3-1 and 32.In the illustrated example the diameter of surface 134 is greater thanthat of surface 138.

Portion 132 also includes a frusto-conical surface 136 intersecting theend of surface 134 remote from end 111) and of smallest diameter at itscircle of juncture with surface 134. Portion 132 further includes afrustoconical surface 138 joining cylindrical surface 130 andfrusto-conical surface 136. In the illustrated example surfaces 136 and138 are inclined with respect to the axis of housing 32 at angles ofabout degrees and 45 degrees, respectively.

Extending from portion 128 through portion 114 and portion 124 tofrusto-conical surface 138 is a longitudinal keyway or vent passage 148at one side of opening 112 and in open communication with portion 128and surface 138 and in effect forming a part of opening 112. Pas sage148 is also in open communication with end 118.

Housing 32 in addition includes an external cylindrical surface 142extending from end 108 to end 118 which surface in the illustratedexample is of the same diameter as surface 184 of housing 30.

Housings 38 and 32 can be plugged together, with ends 76 and 118confronting each other and with surface received in and frictionallyengaging surface 134 to provide the waterseal referred to betweenhousings 30 and 32, until frusto-conical surface 186 engagesfrusto-conical surface 138. The parts are dimensioned so that this lastengagement can take place, that is, the axial length of surface 188 issuificient that the engagement in question is not prevented by anengagement of surface 102 and end 111).

Frusto-conical surfaces 136 and 138 provide a circumferential relief thepurpose of which will appear.

As shown by FIGS. 3 and 11 predetermined amounts of mastic or fillermaterial 144 are placed in portion 86 of opening 78 of housing 30 and inportion 128 of opening 112 of housing 32. In the case of housing 38 themastic material 144 is shown as a mass extending substantially fromchamfer 87 to the axial midportion of portion 86, and in the case ofhousing 32 the mastic material 144 is shown as a mass extendingsubstantially from chamfer 122 to the axial midportion of portion 120.

For best results attention must be given to the material selected formastic material 144. It should have high dielectric strength, low powerfactor, no moisture absorptivity, stability with respect to bothchemical and physical properties, especially viscosity, at temperaturesat least between about minus 40 and about plus 140 degrees Fahrenheit,high corona resistance and no toxicity. It should be ageless bothphysically and chemically, compatible with, non-corrosive and have atendency to wet or adhere to the surfaces of the materials with which itcomes in contact, the latter being desirable in order to preventmoisture creepage. It has been found that a preparation soldcommercially as Silicone compound is admirably suited for use as mastic144 and in the discussion which follows it will be assumed withoutlimitation that this is the material employed.

For a purpose which will appear housing 32 is initially provided with adisposable sleeve 146 (FIG. 11) of any suitable rigid or semi-rigidmaterial. Sleeve 146 is beveled at one end which engages surface 138 andhas an outer surface snugly engaging surface 134 and a length suflicientso that the other end of sleeve 146 projects a predetermined distancebeyond end 110 of housing 32. As shown the inside diameter of sleeve 146is greater than the diameter of surface 130.

Also for a purpose which will appear a solid disposable pin 148 (FIGS. 7and 8) of any suitable rigid material is initially assembled with socketmember 28. Pin 148,

which defines an axis, has a cylindrical surface 150 Within andfrictionally engaging socket portion 44. Axially adjacent portion 150and also within socket portion 44 pin 148 has a frusto-conical surface152 providing a bevel at one end of pin 148. Pin 148 further has a planeannular flange surface 154 perpendicular to the axis of pin 148 andterminating the end of surface 158 remote from frusto-conical surface152. Surface 154 engages and covers the open end of socket portion 44and the corresponding end of sleeve 48, the outside diameter of surface154 being substantially equal to the outside diameter of sleeve 48.Axially adjacent surface 154 and intersecting surface 154 at the outerperiphery thereof pin 148 has a cylindrical surface 156. Axiallyadjacent and intersecting surface 156 pin 14-8 has a frusto-conicalsurface 158 of largest diameter at its circle of juncture with surface156. Axially adjacent and intersecting surface 158 pin 148 has acylindrical surface 168. Axially adjacent surface 160 pin 148 has acylindrical surface 162 of smaller diameter than surface 160 but of atleast as great diameter as surface 118. Pin 148 also has a plane annularsurface 164 joining surfaces 168 and 162. Axially adjacent surface 162pin 148 has a frusto-conical surface 166 which at its circle of largestdiameter intersects surface 162. Surface 166 provides a bevel at the endof pin 148 remote from frusto-conical surface 152.

The desired electrical connection between wires 14 and 28, utilizing theassemblies shown in FIGS. 1 and 7 and housings 38 and 32 as shown inFIGS. 3 and 11 with mastic material 144 therein, is effected briefly bypushing plug member 26 and the end of cable 16 adjacent thereto intohousing 38, pushing pin 148, socket member 28, sleeve 48 and the end ofcable 22 adjacent thereto into housing 32, disposing of sleeve 146 andpin 148, thereupon plugging part 41 of plug portion 42 of plug member 26into socket portion 44 of socket member 28 and simultaneously pushingsurface 188 of housing 30 into surface 134 of housing 32.

The operations referred to in the immediately preceding paragraph willnow be described in greater detail. The installer grasps jacket 18 ofcable 16 in one hand and surface 104 of housing 30 in the other hand,with part 41 of plug member 26 confronting and aligned with end 74 ofhousing 38 and by pushing inserts plug member 26 and related parts apredetermined distance into opening '78, namely, until shoulders 82 ofhousing 38 are between and interengage shoulders 54 of member 26, thusto limit such insertion and thereafter to hold housing 38 inpredetermined position with respect to member 26 (FIGS. 4 and 13). Withthe parts thus positioned, part 41 projects outside housing 38 beyondend 76 thereof, part 43 is within and snugly engages portion 88 ofopening 78, surface 58 is within surface 96, surface 68 is Withinsurface 94, surface 62 is within surface 84 and surface 64 is Withinsurface 98. Socket portion 34 is within portion 86 and spaced from thewall thereof as is beveled surface 37 of cable 16. A portion of jacket18 of cable 16 is in snug frictional engagement with the wall of portion86. The outside diameter of cable 16 is greater than the normal diameterof portion 86, and during the insertion referred to the diameter ofportion 86 is substantially increased, resulting in an external bulgingof housing 38 as shown at 168.

During the insertion in question portion 88 of opening 78 is temporarilyexpanded, this expansion being facilitated by engagement offrusto-conical surfaces 58 and 92.

Entry of cable 16 into housing 30 is facilitated by bevels' 37 and 87.

Relevant parts are dimensioned so that with shoulders 54 and 82 engagingeach other as aforesaid frusto-conical surface 45 coincides with end 76of housing 30, thus to provide visual indication that housing 38 andplug member 26 have been properly assembled, although it is likelythat-the installer will be able to feel the snapping of shoulders 82into engagement with shoulders 54.

The installer grasps jacket 24 of cable 22 in one hand and surface 142of housing 32 in the other hand, with pin 148 confronting and alignedwith end 188 of housing 32 and by pushing inserts pin 148, socket member28 and related parts a predetermined distance into opening 112, namely,until shoulders 116 of housing 32 are between and interengage shoulders56 of socket member 32, thus to limit such insertion and thereafter tohold housing 32 in predetermined position with respect to member 28(FIG. 13). With the parts in this predetermined position, pin 148projects outside housing 32 beyond end 110 thereof, socket portion 44and sleeve 48 are within surface 138, with the latter in snug engagementwith sleeve 48. Surface 68 is within surface 118 and surface 70 iswithin surface 126. Socket portion 38 is within portion 120 and isspaced from the wall thereof as is beveled surface 39 of cable 22. Aportion of jacket 24 of cable 22 is in snug frictional engagement withthe wall of portion 120. The outside diameter of cable 22 is greaterthan the normal diameter of that part of portion 128 adjacent end 188,and during the installation referred to the diameter of portion 128 issubstantially increased, resulting in an external bulging of housing 32as shown at 178.

During the insertion in question portion 114 of opening 112' istemporarily expanded, this expansion being facilitated by engagement offrusto-conical surfaces 128 and 166. Entry of cable 22 into housing 32is facilitated by bevels 39 and 122.

Relevant parts are dimensioned so that with shoulders 56 and 116engaging each other as aforesaid annular surface 164 coincides with theexposed end of sleeve 146, thus to provide visual indication thathousing 32 and socket member 28 have been properly assembled, althoughit is likely that the installer Will be able to feel the snapping ofshoulders 116 into engagement with shoulders 56.

Pin 148 and sleeve 146 are then removed, as by a pair of pliers, andthrown away.

During the insertion of socket member 28, sleeve 48 and related partsinto housing 32 the latter exerts a fric tional drag on sleeve 48tending to move sleeve 48 with respect to socket member 28 toward socketportion 38. Stop 50 retains sleeve 48 in the illustrated positionagainst the frictional drag.

The electrical connection between wires 14 and 20 is then completed byplugging part 41 of plug member 26 into the open end of socket portion44 of socket member 28. Entry of part 41 into portion 44 is facilitatedby bevel 52, and during this operation portion 44 and sleeve 48 aresomewhat expanded radially, thus frictionally to grip part 41. The Wallof housing 32 enhances this grip. Simultaneously housing 38 and 32interengage each other, and more specifically, frusto-conical surface106 and cylindrical surface 106 of housing 38 enter surface 134 ofhousing 32 until frusto-conical surface 186 engages frustoconicalsurface 138 of housing 32. As stated and shown, this engagement limitsthe interengagement of housings 31) and 32. Frusto-conical surface 186facilitates entry of end '76 of housing 38 into end 118 of housing 32.Since the diameter of surface 188 is greater than the normal diameter ofsurface 134, surface 134, the radially adjacent portion of the wall ofhousing 32 and surface 142 expand radially outwardly to produce a bulgeas shown at 172 in FIG. 13.

The frictional engagement of surfaces 106 and 134 creates an effectivewaterseal between housings 38 and 32.

The outward expansion of surface 134 is accompanied by a radial outwardexpansion of frusto-conical surface 136, this latter expansion occurringin pivotal fashion about the circle of juncture between surfaces 136 and138, until with surface 186 engaging surface 138 surface 136 formssubstantially an unbroken cylindrical extension of surface 134. Were itnot for frusto-conical surface 136, that is, if surface 134 normallywere continuous from end to surface 138, the outward expansion thereofwould be accompanied by the production of a fillet of material betweensurfaces 134 and 138 and this fillet would tend undesirably to forcesurface 186 away from surface 138. Thus the relief defined by surfaces136 and 138 serves the function of assuring that housing 38 is fullyplugged into housing 32.

The action of mastic material 144 during the assembling of plug member26 (and related parts) with housing 30 and during the assembling ofsocket member 28 (and related parts) with housing 32 will now bedescribed, attention first being given to the mastic material 144 inhousing 38.

Plug member 26 engages and essentially pierces material 144, making anaxial hole therethrough. During this piercing, which is facilitated bythe reduced diameter of part 41 with respect to part 43, there may besome axial displacement of material 144 toward end 76, but in any event,the piercing is completed by the time part 41 enters surface 84. Thus atthis point practically all of mastic material 144 which was originallyin housing 38 is for practical purposes trapped against further movementtoward end 76 although it can move substantially freely toward end 74.To permit this free movement it is preferable that part 41 enter surface84 prior to the time bevel 37 enters end 74 so that movement of material144 is not impeded by trapped air. Then as part 43 enters material 144,material 144 is forced to move toward end 74. When bevel 37 does enterend 74, considerable hydraulic force is built up which drives allremaining air through the highly frictional keyway 98, followed bymaterial 144, so that keyway 98 will eventually be completely filledwith material 144. To assure that this will be so, it is desirable thathousing 30 initially contain an excess of material 144. This excess willbe forced completely through keyway 98 and can then be wiped off.

Pin 148 and, later, socket member 28 engage and essentially piercematerial 144, making an axial hole therethrough. During this piercing,which is facilitated by the fact that pin portion 162 is relativelyquite small, there may be some axial displacement of material 144 towardend 110, but in any event, the piercing is completed by the time pinportion 162 enters surface 118. Thus at this point practically all ofmastic material 144 which was originally in housing 32 is for practicalpurposes trapped against further movement toward end 110, althoughdesirably it can move substantially freely toward end 108. To permitthis free movement it is preferable that portion 162 enter surface 118prior to the time bevel 39 enters end 108, so that movement of material144 toward end 108 is not impeded by trapped air. Then as pin portion160 enters material 144, material 144 is forced to move toward end 108.So that pin portion 164 and the wall of portion 120 of opening 112 exertas little frictional force on material 144 as possible, the diameter ofportion 169 is as small as possible consistent with providing shoulder164. When bevel 39 does enter end 198, considerable hydraulic force isbuilt up which drives all remaining air through the highly frictionalkeyway 140 followed by material 144, so that keyway 144) eventually willbe completely fill with material 144. To assure that this will be so, itis desirable that housing 32 initially contain an excess of material144. This excess will be forced completely through keyway into theannular space between pin 148 and sleeve 146 and will mostly be removedwith sleeve 146. However, a residuum of material 144 desirably adheresto surface 138, and this residuum serves to fill or substantially fillthe annular space between the open end of socket member 28 and surface76 when housings 30 and 32 are plugged together. Pin 148 also serves toprevent material 144 from undesirably entering socket portion 44 as thelatter proceeds through material 144.

In net result mastic material 144 completely fills all parts of portions80, 86, 88, 114, 120 and 124 of openings 78 and 112 not otherwiseoccupied by members 26 and 28 and cables 16 and 22, as well as all partsof keyways 98 and 14%.

To facilitate the aforesaid piercing of material 144 by member 26, pin148 and member 28, it is desirable that the annular spaces between thewall of opening 78 and member 26, on the one hand, and between the wallof opening 112 and member 28, on the other hand, have relatively largedimensions in planes perpendicular to the axes of members 30 and 32. Tothat end it may be beneficial to enlarge portion 120 of opening 112 ofhousing 32 as shown at 174 from a location axially adjacent surface 128to a location axially between surface 128 and end 108. Housing 30 is notshown as having an enlargement similar to enlargement 174 inasmuch asthe diameter of part 43 of plug member 26 is smaller than the outsidediameter of sleeve 48, although in some cases this may be desirable.

It is to be noted that, due to their resiliency, housings 30 and 32 maybe used with cables of varying outside diameters.

Furthermore, an assembly comprising either housing 30 and related partsor housing 32 and related parts can be used to make an electricalconnection with means different from the other illustrated housing andrelated parts.

Housings 3t) and 32 can conveniently be molded of synthetic rubber, ofwhich properly compounded S.B.R.

If? (Styrene Butadiene Rubber) is a highly satisfactory example.

Surfaces 82 and 116 are as nearly perpendicular to the axes of housings30 and 32 as is possible consistent with sound molding methods.

As far as cables 16 and 22 are concerned, jackets 18 and 24, the primarypurpose of which is to provide physical protection and not electricalinsulation, may be, for example, of properly compounded neoprene,polystyrene, polyvinyl or even lead.

It is also to be noted that in the event moisture enters a hole throughjacket 18 or 24, such moisture may proceed toward the electricalconnection between covering 18 or 24 and the cable insulation in a sortof capillary action. Such moisture will be blocked from further progresstoward the metallic parts of the connection by the mastic material 144at bevel 37 or 39, and no damage will be done.

To revert to mastic material 144, this material can vary from a lowviscosity material to a high viscosity material to a solidifyingmaterial. Low viscosity material may be used where capillary propertiesare desired, and with this sort of material, of which Silicone compoundis an example, there is possible bleeding of the material, this bleedingconsisting of a migration of the dielectric component of the material toreinforce the electrical properties of the surfaces which it engages.High viscosity material, of which a suitable example is a low petroleumend point compound, exhibits little migratory function and is sticky,having a true affinity for the materials which it engages, and functionsprimarily as a dielectric bulk filler. A solidifying material, of whichsuitable examples are twopart rubber compounds or epoxies which could bemixed in the field and inserted into housing 30 and/or housing 32, couldbe used to advantage Where mechanical resistance to nonaxial loading isdesired. Low and high viscosity materials have the desirable function ofdressing and re-dressing the surfaces which they engage over indefiniteperiods of time, thus maintaining electrical properties in the face ofnatural movements and strains to which the connection may be subjected.

It has been found desirable, just prior to the insertion of members 26and 28 into housings 30 and 32, respectively, to put light coatings ofmastic material 144 on those parts of cable jackets 18 and 24 which areto be within housings 30 and 32. This eases the insertion of cables 16and 22 into housings 30 and 32, respectively, and also assures thatconcavities on jackets 18 and 24 will be filled with mastic material144. Material 144 for this purpose may be obtained by inserting member26 a short way into material 144 in housing 30 and removing member 26from housing 30 and by inserting pin 148 a short way into material 144in housing 32 and removing pin 148 from housing 32.

Members 26 and 28 may be zone annealed at socket portions 34 and 38 toenhance crimpability without impairing strength at other locations.

The invention is well adapted to the attainment of the stated objectsand advantages and others.

Since many changes which will occur to those skilled in the art can bemade without departing from the invention the details of the illustratedexample are not to be taken as limitations upon the invention except asthose details may be included in the appended claims.

What is claimed is:

1. Electrical cable connector means comprising a housing of resilientinsulating material having first and second ends and an opening in opencommunication with each said end, said opening including a constrictedportion spaced from each said end, a first end portion having aresiliently expansible internal surface between said constricted portionand said first end for gripping the jacket of the cable and a second endportion between said constricted portion and said second end, saidhousing further having a resiliently expansible internal watersealsurface between said constricted portionand said second end and in opencommunication with said second end and an internal vent passage in theform of a keyway having a first end in open communication with saidfirst end portion and a second end in open communication with saidsecond end of said housing, said keyway extending through saidconstricted portion and along said second end portion of said opening, apredetermined amount of mastic material in said first end portion ofsaid opening, an elongate metallic connector member having a connectingpart in the form of a receptacle at the first end thereof, a socket atthe second end thereof to receive for attachment thereto the conductingmeans of the cable and a shouldered portion between said receptacle andsaid socket, and a disposable rigid pin having a free end and an end insaid receptacle, said opening adapted to receive the assembly of saidpin, said connector member and said cable, with said free end of saidpin entering said first end portion of said opening, until saidshouldered portion of said connector member engages said constrictedportion of said opening and the cable jacket enters said first endportion of said opening and engages said resiliently expansible internalsurface of said first end portion, so that during the insertion of saidassembly into said opening air and a part of said mastic material willbe forced through said keyway.

2. Electrical cable connector means comprising a housing of resilientinsulating material having first and second ends and an opening in opencommuication with each said end, said opening including a constrictedportion spaced from each said end, a first end portion having aresiliently expansible internal surface between said constricted portionand said first end for gripping the jacket of the cable and a second endportion between said constricted portion and said second end, saidhousing further having an external waterseal surface in opencommunication with said second end and a vent passage in the form of akeyway having a first end in open communication with said first endportion and a second end in open communication with and at said secondend of said housing, said keyway extending through said constrictedportion and along said second end portion of said opening, apredetermined amount of mastic material in said first end portion ofsaid opening and an elongate metallic connector member having aconnecting part in the form of a plug at the first end thereof, a socketat the second end thereof to receive for attachment thereto theconducting means of the cable and a shouldered portion between said plugand said socket, said opening adapted to receive the assembly of saidconnector member and said cable, with said plug entering said first endportion of said opening, until said shouldered portion of said connectormember engages said constricted portion of said opening and the cablejacket enters said first end portion of said opening and engages saidresiliently expansible internal surface of said first end portion, sothat during the insertion of said assembly into said opening air and apart of said mastic material will be forced through said keyway.

3. Electrical cable connector means comprising a housing of resilientinsulating material having first and second ends and an opening in opencommunication with each said end, said opening including a constrictedportion spaced from each end, a first end portion having a resilientlyexpansible internal surface between said constricted portion and saidfirst end for gripping the jacket of the cable and a second end portionbetween said constricted portion and said second end, said housingfurther having a waterseal surface in open communication with saidsecond end and an internal vent passage having a first end in opencommunication with said first end portion and a second end in opencommunication with said second end portion of said opening, said ventpassage extending through said constricted portion and along said secondend portion of said opening, a predetermined amount of mastic materialin said first end portion of said opening,

and an elongate metallic connector member having a connecting part atthe first end thereof, a socket at the second end thereof to receive forattachment thereto the conducting means of the cable and a shoulderedportion between said connecting part and said socket, said openingadapted to receive the assembly of said connector member and said cable,with said connecting part entering said first end portion of saidopening, until said shouldered portion of said connector member engagessaid constricted portion of said opening and the cable jacket enterssaid first end portion of said opening and engages said resilientlyexpansible internal surface of said first end portion, so that duringthe insertion of said assembly into said opening air and a part of saidmastic material will be forced through said vent passage.

4. Electrical cable connector means comprising a housing of resilientinsulating material having first and second ends and an opening in opencommunication with each said end, said opening including a constrictedportion spaced from each said end, a first end portion having aresiliently expansible internal surface between said constricted portionand said first end for gripping the jacket of the cable and a second endportion between said constricted portion and said second end, saidhousing further having an internal vent passage having a first end inopen communication with said first end portion and a second endeffectively in open communication with said second end of said housing,said vent passage extending through said constricted portion and alongsaid second end portion of said opening, a predetermined amount ofmastic material in said first end portion of said opening, and anelongate metallic connector member having a connecting part at the firstend thereof, a socket at the second end thereof to receive forattachment thereto the conducting means of the cable and a shoulderedportion between said connecting part and said socket, said openingadapted to receive the assembly of said connector member and said cable,with said connector part entering said first end portion of saidopening, until said shouldered portion of said connector member engagessaid constricted portion of said opening and the cable jacket enterssaid first end portion of said opening and engages said resilientlyexpansible internal surface of said first end portion, so that duringthe insertion of said assembly into said opening air and a part of saidmastic material will be forced through said vent passage.

5. Electrical cable connector means for releasably joining a pair ofcables, said means comprising a pair of housings of resilient insulatingmaterial, each said housing having a pair of ends and an opening in opencommunication with each said end of its housing, each said openingincluding a constricted portion spaced from each said end of its saidhousing, each said opening further including a first end portion betweensaid constricted portion thereof and said first end of its said housingand having a resiliently expansible internal surface between saidconstricted portion thereof and said first end thereof for gripping thejacket of one of said cables, each said opening further having'a secondend portion between said constricted portion thereof and said second endof its said housing, each said housingfurther having an internal ventpassage having a first end in open communication with said first endportion of its said housing and a second end effectively in opencommunication with said second end of its said housing, each said ventpassage extending through said constricted portion of said opening ofits said housing and along said second end portion of said opening ofits said housing, a predetermined amount of mastic material in saidfirst end portion of each said opening, each said housing further havinga waterseal surface in open communication with said second end thereof,said waterseal surfaces adapted for releasable interfitting engagementwith each other to form a Waterproof joint therebetween, and a pair ofelongate metallic connector members, each said connector member having aconnecting part at the first end thereof, a socket at the second endthereof to receive for attachment thereto the connecting means of one ofsaid cables to form an assembly therewith and a shouldered portionbetween said connecting part of its said connector member and saidsocket of its said connector member, said connecting parts adapted forreleasable interfitting engagement with each other, said opening of oneof said housings adapted to receive one of said assemblies, with saidconnecting part thereof entering said first end portion of said openingof said one housing, until said shouldered portion of said one assemblyengages said constricted portion of said opening of said one housing andthe cable jacket of said one assembly enters said first end portion ofsaid opening of said one housing and engages said resiliently expansibleinternal surface thereof, said opening of the other of said housingsadapted to receive the other of said assemblies, with said connectingpart thereof entering said first end portion of said opening of saidother housing, until said shouldered portion of said other assemblyengages said constricted portion of said other housing and the cablejacket of asid other assembly enters said first end portion of saidopening of said other housing and engages said resiliently expansibleinternal surface thereof, so that during the insertion of saidassemblies into said openings as aforesaid, air and a part of saidmastic material will be forced through said vent passages, andthereafter said connecting parts of said connector members can beinterfitted as aforesaid simultaneously with the interfitting of saidwaterseal surfaces.

6. A method of terminating an electrical cable by means of a housing ofresilient insulating material having an opening therethrough, saidopening including a constricted portion and an end portion having aresiliently expansible internal surface between said constricted portionand one end of said opening and an elongate metallic connector memberhaving a connecting part at one end thereof, a socket at the other endthereof and a shouldered portion therebetween, said method comprisingthe steps of placing a predetermined amount of mastic material in saidend portion of said opening, attaching said socket to the conductingmeans of said cable and thereafter inserting said connector member, withsaid cable attached therto, into said one end of said opening until saidshouldered portion engages said constricted portion and the cable jacketenters said end portion and engages said resiliently expansible internalsurface, and during the inserting step venting air and a part of saidmastic material from said end portion of said opening.

7. A method of terminating an electrical cable by means of a housing ofresilient insulating material having an opening therethrough, saidopening including a constricted portion and an end portion containingmastic material and having a resiliently expansible internal surfacebetween said constricted portion and one end of said opening and anelongate metallic connector member having a connecting part at one endthereof, a socket at the other end thereof and a shoulder, said methodcomprising the steps of attaching said socket to the connecting means ofsaid cable and thereafter inserting said connector member into saidopening until said constricted portion overlaps said shoulder with thecable jacket engaging said resiliently expansible surface, and duringthe inserting step venting air and a part of said mastic material fromsaid end portion of said opening.

References Cited in the file of this patent UNITED STATES PATENTS2,223,991 Horni Dec. 3, 1940 2,700,140 Phillips Ian. 18, 1955 2,753,534Sprigg July 3, 1956

3. ELECTRICAL CABLE CONNECTOR MEANS COMPRISING A HOUSING OF RESILIENTINSULATING MATERIAL HAVING FIRST AND SECOND ENDS AND AN OPENING IN OPENCOMMUNICATION WITH EACH SAID END, SAID OPENING INCLUDING A CONSTRICTEDPORTION SPACED FROM EACH END, A FIRST END PORTION HAVING A RESILIENTLYEXPANSIBLE INTERNAL SURFACE BETWEEN SAID CONSTRICTED PORTION AND SAIDFIRST END FOR GRIPPING THE JACKET OF THE CABLE AND A SECOND END PORTIONBETWEEN SAID CONSTRICTED PORTION AND SAID SECOND END, SAID HOUSINGFURTHER HAVING A WATERSEAL SURFACE IN OPEN COMMUNICATION WITH SAIDSECOND END AND AN INTERNAL VENT PASSAGE HAVING A FIRST END IN OPENCOMMUNICATION WITH SAID FIRST END PORTION AND A SECOND END IN OPENCOMMUNICATION WITH SAID SECOND END PORTION OF SAID OPENING, SAID VENTPASSAGE EXTENDING THROUGH SAID CONSTRICTED PORTION AND ALONG SAID SECONDEND PORTION OF SAID OPENING, A PREDETERMINED AMOUNT OF MASTIC MATERIALIN SAID FIRST END PORTION OF SAID OPENING, AND AN ELONGATE METALLICCONNECTOR MEMBER HAVING A CONNECTING PART AT THE FIRST END THEREOF, ASOCKET AT THE SECOND END THEREOF TO RECEIVE FOR ATTACHMENT THERETO THECONDUCTING MEANS OF THE CABLE AND A SHOULDERED PORTION BETWEEN SAIDCONNECTING PART AND SAID SOCKET, SAID OPENING ADAPTED TO RECEIVE THEASSEMBLY OF SAID CONNECTOR MEMBER AND SAID CABLE, WITH SAID CONNECTINGPART ENTERING SAID FIRST END PORTION OF SAID OPENING, UNTIL SAIDSHOULDERED PORTION OF SAID CONNECTOR MEMBER ENGAGES SAID CONSTRICTEDPORTION OF SAID OPENING AND THE CABLE JACKET ENTERS SAID FIRST ENDPORTION OF SAID OPENING AND ENGAGES SAID RESILIENTLY EXPANSIBLE INTERNALSURFACE OF SAID FIRST END PORTION, SO THAT DURING THE INSERTION OF SAIDASSEMBLY INTO SAID OPENING AIR AND A PART OF SAID MASTIC MATERIAL WILLBE FORCED THROUGH SAID VENT PASSAGE.